Vibration dampening and pressure relieving innersole for cycling shoe

ABSTRACT

Disclosed herein are innersoles for cycling shoes and to cycling shoes including such innersoles.

RELATED CASES

Priority is hereby claimed to commonly-owned and co-pending ProvisionalApplication No. 61/384,700 filed on Sep. 20, 2010, which is incorporatedherein by reference in its entirety.

TECHNICAL FIELD

The present invention relates to an innersole for a bicycle shoe thatreduces vibration and hot spots and pressure at the point of contactwith the pedal.

BACKGROUND

In most athletic activities, footwear is designed to absorb shock andimpact of running, walking, jumping or bouncing activities, which hasbeen accomplished by utilizing many combinations of supporting shapesand cushioning materials.

Cycling shoes, unlike other forms of athletic footwear, have verydifferent design consideration. During cycling, a user's cycling shoedoes not impact the ground, or other surfaces, because the shoe isattached to or supported by a pedal. Therefore, the cushioning or impactabsorbing characteristics of a cycling shoe are not the same as would bedesirable or necessary for other athletic shoes, for which impactabsorption is important, such as running, jumping or walking, duringwhich the heel is often a primary impact site. While some cycling shoesare intended for walking purposes as well, many are designed solely forpedaling.

In addition, reduced weight is an advantage in cycling. Therefore,cycling shoes are designed to be lightweight.

During cycling, it is also desirable to maximize the energy transferenergy from a cyclist's foot, to the pedal of the bike. To facilitateenergy transfer, it is desirable to maintain the cyclist's foot in fixedrelation to the pedal and/or cleat. Therefore, cycling shoes are oftenmade of stiff materials, such as carbon fiber composites, whichminimizes flexing and shifting during the cycle stroke.

Unlike other sports shoes, cycling shoes have a singular, non-impactcontact point, often resulting in numbness and pain. This non-impactcontact region is located in the interface between the forefoot and thepedal, and is often referred to as the “hot spot” region. Long or mediumdistance cycling exposes the foot to continuous pressure and vibrationin the hot spot, and the effect is different in kind than a force orbouncing pressure that can vary in location and over time in otheractivities. In cycling, even though there is no ground impact toconsider, there is a repetitive and sometimes nearly constant pressure,vibration, friction and sheer forces exerted on the hot spot, as theresult of the steady, repetitive movement during the pedal stroke. Theproblems associated with the hot spot can be exacerbated in the cleatregion of clipless cycling shoes.

There is a need for a cycling innersole that can relieve pressure,reduce vibration, sheer and/or friction at the hot spot, and for acycling shoe including such an innersole.

SUMMARY

The present disclosure is directed to an innersole for a cycling shoewith a cleat region, comprising an innersole body, a recessed regiondefined in the innersole body, corresponding to the cleat region of thecycling shoe, an insert disposed in the recessed region, the insertcomprising a first material layer comprising a thickness of betweenabout 0.010″ and 0.150″ and a second material layer comprising athickness between about 0.0005″ to about 0.010″.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other features and advantages will be apparent fromthe following more particular description of exemplary embodiments ofthe disclosure, as illustrated in the accompanying drawings, in whichlike reference characters refer to the same parts throughout thedifferent views. The drawings are not necessarily to scale, emphasisinstead being placed upon illustrating the principles of the disclosure.In the drawings,

FIG. 1 is a top view of a cycling shoe innersole according to thepresent disclosure;

FIG. 2 is a bottom view of the innersole shown in FIG. 1;

FIG. 3 is a bottom perspective view of the innersole shown in FIG. 1;

FIG. 4 is a side view of the innersole shown in FIG. 1;

FIG. 5 is a top view of the innersole shown in FIG. 1, without theinsert;

FIG. 6 is a cross-sectional view of the innersole shown in FIG. 5,without the insert, through line 6-6;

FIG. 7 is a cross-sectional view of the innersole shown in FIG. 1,through line 7-7;

FIG. 8 is a cross-sectional view of another embodiment of the innersoleshown in FIG. 1, through line 7-7;

FIG. 9 is a cross-sectional view of another embodiment of the innersoleshown in FIG. 1, through line 7-7; and

FIG. 10 is a cross-sectional view of another embodiment of the innersoleshown in FIG. 1, through line 7-7;

DETAILED DESCRIPTION

The present disclosure relates to an innersole for a cycling shoe, whichrelieves problems in the “hot spot” region, and to cycling shoescomprising such an innersole. The “hot spot region,” as used herein,means the interface region between the forefoot, cleat and/or pedal. Theinnersole comprises an insert disposed in the hot spot region.

Space in a cycling shoe is very limited, especially in the forefoot.Therefore, the present inserts comprises relatively thin layers of verylow durometer gel. By using low durometer gels, the constant pressureand vibrations from the road transmitted up to the hot spot region canbe relieved and/or dampened. The selection of gel material is differentthan usual innersole materials that would be designed to absorb impacts.The low durometer gels function like an added layer of fat, takingpressure from the foot, rather than relieving shocks. The very lowdurometer materials are capable of absorbing micro-vibrations from theroad that also contribute to numbness in the hot spot region.

The size, shape and configuration of the inserts are user-selected inthe present design to correspond to the size, shape and configuration ofthe hot spot region for a particular shoe design. Thus, in the presentcycling innersoles, the cushioning area is minimized, unlike otherathletic innersoles, where it is desirable to maximize the cushioningarea.

FIGS. 1-7, when taken together, illustrate one exemplary innersole 10according to the present disclosure. As shown, innersole 10 comprises aninnersole body 18 with opposing top and bottom surfaces 10 a,b, aforefoot region 12, an instep region 14, and a cupped heel region 16. Aninsert 20 is disposed in the forefoot region 12. As noted above, it isdesirable for innersoles for cycling shoes to be as thin and lightweightas possible. Therefore, innersole 10 can comprise a thickness T₀ rangingfrom about 0.150″ to about 0.300″.

Insert 20 can comprise a polymeric material layer 30 and an outer layer40 and, in some embodiments, an optional layer 50 can be disposedadjacent to the polymeric layer 30, and opposite the outer layer 40 (asshown in FIGS. 7-9). Alternatively, as shown in FIG. 10, the adhesivematerial 24 can be eliminated, allowing the insert 20 to be adhereddirectly to the innersole body 18 in the recessed region 22.

The present inserts may be manufactured using the materials andtechniques disclosed in U.S. Pat. No. 7,827,704 and U.S. PublicationNos. US 2008/0034614 and US 2009/0255625, which are incorporated hereinby reference in their entirety.

An insert thickness of about 0.090″ has been found effective forreducing or eliminating the hot spot affect in cleated cycling shoes,but the thickness maybe varied depending on a variety of factorsincluding, but not limited to, the shoe design, cleat dimensions, pedaldimensions, material, and the like. Accordingly, inserts 20 can comprisea thickness ranging from about 0.020″ to about 0.150″, more particularlyabout 0.040″ to about 0.120″, more particularly still about 0.060″ toabout 0.100″.

In some embodiments, a traditional sock lining material 80 may bedisposed on the top surface 10 a of the innersole 10 to, for example,absorb sweat. Suitable sock lining materials include, but are notlimited to, polyester, nylon, polypropelene, wool, and the like,including both wovens, nonwovens, and films thereof, and combinations ofthe foregoing.

As shown best in FIG. 5, innersole body 18 comprises a recessed region22 with sidewalls 22 a, formed in the forefoot region 12, for receivingthe insert 20 therein. Recessed region 22 comprises a depth D, which mayvary depending on a variety of factors including, but not limited to,the material from which the innersole body 18 is formed, the shoe designand materials, the cleat design and dimensions, the pedal dimensions,and the like. A suitable depth D is sufficient to accommodate thethickness of the insert 20 (as shown in FIGS. 7 and 10), although it canbe varied to allow the insert to be recessed (as shown in FIG. 9), or toextend outside of the recess (as shown in FIG. 8).

Alternatively, although not illustrated herein, innersole body 18 cancomprise an opening or hole extending from the top surface to the bottomsurface, for receiving the insert 20 therein, and in such an embodiment,the sidewalls of the insert 20 could be attached to the sidewalls of theopening or hole, using a variety of techniques, such as gluing, bonding,welding, and the like.

The innersole body 18 can be formed from any material comprisingsufficient structural integrity to be formed into predetermined shapes,including polymeric materials; sufficient softness and/or pliability toprovide comfort against a foot; and that is capable of withstanding theenvironment in which it is intended to be used, without substantialdegradation. Suitable materials for innersole body 18 include, but arenot limited to, polyurethane, polyethylene, ethylene vinyl acetate(EVA), including open or closed cell foams thereof, and combinations ofthe foregoing.

The recessed region 22 can be formed in the forefoot region 16 using avariety of techniques, including during molding, or by molding theinnersole body 18 without the recessed region, and forming the recessedregion by compressing the material in that region. to create therecessed region.

Suitable materials for layers 30 and 40 of the insert 20 are describedin the above-referenced applications. The gel can comprise one or morelayers of any material or combination of materials having sufficientstructural integrity to be formed into predetermined shapes, and that iscapable of withstanding the environment in which it is intended to beused, without substantial degradation. Examples of suitable materialsinclude viscoelastic polymeric materials, and the like. Examples ofsuitable polymeric materials include, but are not limited to,thermosetting polymeric materials, elastomeric polymeric materials,thermoplastic materials, including thermoplastic elastomeric materials,and combinations comprising at least one of the foregoing. Some possiblepolymeric materials include, but are not limited to, polyurethane,silicone, and/or the like, and combinations comprising at least one ofthe foregoing materials.

In such instances, it has been found that viscoelastic polymeric gelsare suitable. In one exemplary embodiment, the gel insert comprises apolyurethane gel material with a durometer below 60 Shore 00. In anotherexemplary embodiment, the gel insert comprises a gel material with a 00Shore 60 or below. Even lower durometer ranges have been used dependingon the level and type of vibration dampening desired and the amount ofpressure relief.

One example of a suitable gel is a polyurethane gel comprising adurometer ranging from about 0.01 Shore 00 to less than or equal toabout 70 Shore A, more particularly less than 70 Shore 00, moreparticularly still less than 60 Shore 00. The durometer of the polymercan be determined by those of ordinary skill in the art using tools suchas durometers or penetrometers.

Formation of the gel can take place by a variety of methods known tothose of skill in the art. For example, formation of a polyurethane gelcan comprise reacting suitable pre-polymeric precursor materials e.g.,reacting a polyol and an isocyanate in the presence of a catalyst.

The gel can comprise a thickness of about 0.010″ and 0.150″, moreparticularly about 0.040″ and 0.110″, and more particularly still about0.060″ and 0.100″.

In many embodiments, the low durometer gel has a film, fabric, laminateor other material covering its bottom surface where it comes in contactwith the bottom of the bicycle shoe. This can also be desirable sincethe low durometer gel exposed can in many cases be sticky.Alternatively, it can be covered by a fabric, non-woven, other film, orfilm laminate or any proper covering material.

The optional outer layer can comprise any material capable of providingsufficient elasticity to prevent tearing and/or stretching when a forceis applied thereto; sufficient structural integrity to be formed intopredetermined shapes; and that is capable of withstanding theenvironment in which it is intended to be used (e.g., repetitive slidingand the like), without substantial degradation. The outer layer also canbe selected to facilitate the handling of the polymer layer, which cancomprise adhesive characteristics in some instances. Therefore, aftermolding, the outer layer can be selected to comprise a relativelynon-tacky surface and a relatively smooth feel to the human touch.

Some possible materials for the outer layer include polyolefins,polystyrenes, PVC, latex rubber, and thermoplastic elastomers (TPEs),and/or the like, and combinations comprising at least one of theforegoing materials. Some possible TPE materials include polyurethane,silicone, and/or the like, and combinations comprising at least one ofthe foregoing materials.

Other possible materials for the outer layer include, but are notlimited to, fabrics, paper, plastic (e.g., polyester, nylon, polyolefin,Teflon, silicon, EVA, Vinyl, polyethylene, polyvinyl chloride (PVC), andthe like) metal, metallized plastic, and/or the like, and combinationscomprising at least one of the foregoing materials. Polyurethane filmcan be desirable due to its combination of durability and elasticity andsoftness and flexibility.

The outer layer can comprise an elongation of about 100 percent (%) toabout 1500%, more particularly about 200% to about 1000%, and moreparticularly still about 300% to about 700%”.

While PU film or other elastic or somewhat elastic films can be used asthe outer layer, other durable materials can be used for the outer layerincluding knit, woven and nonwoven fabrics, leather, vinyl or any othersuitable material. In some cases the heating or otherwise forming orpre-stretching of materials with more limited stretch can aid in theiruse.

The use of actives in the inner or outer layer or the foam itself can bedesirable, such as the addition of silver or copper based actives to actas an antimicrobial or antifungal agent.

The bottom or top surface of the gel can in some embodiments be coveredby a thin film such as a thin TPE film or 0.0005″ to 0.010″ thick ormore preferably between 0.0006″ to 0.005″ thick.

Any number of thicknesses of film can be used, but polyurethane filmthicknesses of between 0.001 and 0.010″ may be desirable. Thicker filmsare more durable, but they may add to the weight of the innersole.

Outer layer can comprise any thickness capable of allowing the productsto be molded without sticking to the mold. The thickness of the outerlayer can be varied depending upon the application and the desiredthickness for a particular application can be determined using routineexperimentation by those of ordinary skill in the art. The outer layercan comprise a thickness ranging from about 0.2 milli-inch (hereinafter“mil”) to about 60 mil, more particularly from about 0.5 mil to about 30mil, and more particularly still from about 1.0 mil to about 15 mil. Forexample, in instances in which the hand-feel of the products isimportant, it has been found that this can be achieved with relativelythin outer layers. Therefore, in such products it can be desirable touse the thinnest outer layer possible without sacrificing durability.For example, for applications in which a relatively thin outer layer isdesirable, it can comprise a thickness ranging from about 0.2 milli-inchto about 6 mil, more particularly from about 0.5 mil to about 3 mil, andmore particularly still from about 0.6 mil to about 2 mil.

When the durometer of the polymerized layer is such that it is tacky,the tacky material can be exposed if the outer layer is punctured,making the products difficult to handle. In such instances, it can bedesirable to use a thicker outer layer, which can provide increaseddurability in comparison to thinner outer layers. For example, when thepresent materials are used in vibration dampening applications, it canbe desirable for the thickness of the outer layer to be about 50 toabout 60 mil.

It may be desirable to include dimples or thin and thick areas of thegel. Small grooves or channels or raised areas can be molded into thegel on its top or bottom surface to affect the vibration dampening andpressure relief properties as well as the air flow across the gel in theshoe. Deeper channels or perforations in the gel can be desirable foradded breathability or air flow. Deep molded “fingers” or protrusions inthe gel can provide thickness with elimination of some unnecessaryweight and can help move to reduce sheer and also eliminate vibration,which are important in reducing the numbness and “hot spots”.

It may be desirable for the area covered by the insert to be sufficientto cover the maximum adjustment points of the cleat adjustment throughthe ranges of sizes for which it is to be used. Therefore, thedimensions above allow for the fact that the rider can adjust the cleatposition forward in a slide built into the base of most cycling shoes.In some embodiments, multiple size shoes may be fitted from the sameinnersole shape by trimming off the front of the innersole to fit theparticular shoe. Detailed measurements showing the dimensions from theback of the heel to the frontmost cleat attach point in a variety ofsizes of mens and womens cycling shoes are shown below in Tables A andB. The dimensions were measured from the rear of the heel to the cleat,and the dimensions for the gel area as shown in the tables has beenfound suitable for this purpose, but other dimensions can be utilized.

TABLE A WOMEN'S MEASUREMENTS Slide ¾ in Slide ¾ in SIZE SIDIS SHIMANO 365½ in 37 5½ in 5¾ in 38 5¾ in 6 in 39 6 in 40 6¼ in 41 6½ in 42 6½ in6½-6 10/16 43 6 11/16 (6¾ in)

TABLE B MEN'S MEASUREMENTS Slide 1 2/16 in SIZE SIDIS SHIMANO 40 5⅞ in6¼ in (4″ to toe) 41 5 15/16 in 42 6 in 43 44 6½ in 45 46 7 2/16 in 47 7in 48 49 7½ in

It should be noted that the terms “first,” “second,” and the like hereindo not denote any order or importance, but rather are used todistinguish one element from another, and the terms “a” and “an” hereindo not denote a limitation of quantity, but rather denote the presenceof at least one of the referenced items. Similarly, it is noted that theterms “bottom” and “top” are used herein, unless otherwise noted, merelyfor convenience of description, and are not limited to any one positionor spatial orientation. In addition, the modifier “about” used inconnection with a quantity is inclusive of the stated value and has themeaning dictated by the context (e.g., includes the degree of errorassociated with measurement of the particular quantity).

Compounds are described herein using standard nomenclature. For example,any position not substituted by an indicated group is understood to haveits valency filled by a bond as indicated, or a hydrogen atom A dash(“-”) that is not between two letters or symbols is used to indicate apoint of attachment for a substituent. For example, —CHO is attachedthrough the carbon of the carbonyl group. Unless defined otherwiseherein, all percentages herein mean weight percent (“wt. %”).Furthermore, all ranges disclosed herein are inclusive and combinable(e.g., ranges of “up to about 25 weight percent (wt. %), with about 5wt. % to about 20 wt. % desired, and about 10 wt. % to about 15 wt. %more desired,” are inclusive of the endpoints and all intermediatevalues of the ranges, e.g., “about 5 wt. % to about 25 wt. %, about 5wt. % to about 15 wt. %”, etc.). The notation “+1-10% means that theindicated measurement may be from an amount that is minus 10% to anamount that is plus 10% of the stated value.

Finally, unless defined otherwise, technical and scientific terms usedherein have the same meaning as is commonly understood by one of skillin the art to which this disclosure belongs.

While the disclosure has been described with reference to exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes may be made and equivalents may be substituted forelements thereof without departing from the scope of the disclosure. Inaddition, many modifications may be made to adapt a particular situationor material to the teachings of the disclosure without departing fromthe essential scope thereof. Therefore, it is intended that thedisclosure not be limited to the particular embodiment disclosed as thebest mode contemplated for carrying out this disclosure, but that thedisclosure will include all embodiments falling within the scope of theappended claims.

1. An innersole for a cycling shoe with a cleat region, comprising: aninnersole body; a recessed region defined in the innersole body,corresponding to the cleat region of the cycling shoe; an insertdisposed in the recessed region, the insert comprising a first materiallayer comprising a thickness of between about 0.010″ and 0.150″ and asecond material layer comprising a thickness between about 0.0005″ toabout 0.010″.
 2. The cycling shoe of claim 1, wherein the first materialcomprises a polymeric gel with a durometer ranging from about 0.01 Shore00 to 70 Shore
 00. 3. The cycling shoe of claim 1, comprising athickness of less than about 0.300″.